Continuous feed, chemical switching unit

ABSTRACT

Continuous feed, chemical switching unit for supplying an uninterrupted flow of chemical fluid to a processing system including a control unit and a reservoir for containing a predetermined volume of chemical fluid wherein the reservoir is in hydraulic communication with a processing system. A plurality of float level sensors are provided within the reservoir for locating the fluid level in the reservoir wherein at least one level sensor provides an interlock to the processing system when energized to halt the processing system operation, and the other level sensors communicate reservoir level information to the control unit. The switching unit also includes a plurality of replaceable chemical fluid bottles for storing the fluid, e.g. a first active bottle and a second standby bottle, wherein the bottles are in independent hydraulic communication with the reservoir. Each fluid bottle has associated therewith an inert-gas actuated isolation valve for isolating the bottle from the reservoir. A vacuum source is in hydraulic communication with and for drawing a vacuum on the reservoir to cause fluid flow from an active bottle including an inert-gas actuated isolation valve associated therewith for isolating the vacuum source from the reservoir The control unit is responsive to electrical signals from the level sensors, to an input power signal, and to a plurality of user commands, and is operative to generate signals to actuate the vacuum source isolation valve and the bottle isolation valves to switch the source of chemical fluid flow from one bottle to another as the first bottle becomes empty. Finally, an explosion-proof enclosure for housing the switching unit components wherein the enclosure is fitted with an exhaust device to vent explosive gases from the enclosure and is also equipped with a fire extinguishing device.

FIELD

The present invention relates generally to feed chemical devices andmore particularly to continuous feed, chemical devices for supplyingphoto-resist spin-coating systems used in integrated circuit (IC) waferfabrication.

BACKGROUND

In the wafer fabrication process, after the initial preparatory steps ofcleaning and dehydration baking, the wafers undergo a coating step.Wafer coating usually involves the application of two chemicals to thewafer including an adhesion-promoter such as hexamethyldisilizane (HMDS)and a photoresist chemical. After the HMDS is applied to the wafer, thewafer is spun (typically within a track system) to produce a uniformcoating. After the wafer is dry, the photoresist chemical is applied tothe wafer where it is then spun again to produce a uniform coating.

The coating chemicals, due to their volatile nature, are contained inclosed containers. It is known in the art to provide a simple fluiddelivery system which typically consists of a pumping unit andassociated inlet and outlet lines. The pump draws the chemical fluidfrom the container or canister and delivers the chemical to the coatingapparatus where it is then deposited on the wafer.

A typical chemical system, prevalent in the prior art, is schematicallyillustrated in FIG. 1. A feed chemical system 100 includes a fluidchemical 102, used in some processing operation (typically IC waferfabrication), a storage tank or container 103 for holding the fluid 102,a processing system 104 for performing the processing operation andultimately consuming the fluid, and a pumping system 106 for deliveringthe fluid 102 from the storage tank 103 to the processing system 104.The pumping system 106 is communicatively coupled, via a suction pipe108, with the storage tank 103, and a discharge pipe 109 communicativelycouples the pumping system 106 with the processing system 104.

In operation, the pumping system 106 draws the fluid 102 from the tank103 via the suction pipe 108, and pumps the fluid 102 via the dischargepipe 109 to the processing system 104. The pumping system continues todraw on the tank until the level of fluid contained in the tank reachesa predetermined level. When the fluid level in the tank reaches thislevel, the tank is considered "empty" and the process operation must behalted, the pump shut down and the tank either refilled, or removed andreplaced.

A problem with the prior art feed chemical delivery systems is that whenthe fluid supply canister runs dry, chemical fluid flow is interrupted,resulting in miscoating since the pumping or processing operations arenot halted immediately. In the wafer coating process operation, forexample, when the chemical fluid (i.e., photo-resist material) isdepleted from the storage container, the coating applicator continues tooperate for a time until the situation is noticed. During this time theapplicator continues to feed on the wafer surface without dispensing anyphoto-resist material thereby leaving bare, or irregularly orinsufficiently coated areas on the surface of the wafer. Theunacceptable quality of the coatings deposited on the affected wafersresults in scrapping of these units, thereby increasing costs andreducing production yields. In addition, when the chemical fluid isdepleted, the processing system must be halted while the storagecontainer is either replaced by a full container or replenished withmore chemical fluid. Misprocessings also occur frequently when theprocess system is restarted after such an interruption.

Yet another problem caused by interruption of the chemical fluid flow isslowdown in the overall manufacturing throughput. As the chemical fluidflow is depleted, the processing system must be shut down and thethroughput halted. Even if the processing and pumping systems are shutdown at the appropriate time and the manufacturing quality is notimpaired, the production line is nevertheless halted while the chemicalfluid is replenished. Clearly, as chemical fluid flow interruptionsbecome more frequent the throughput of units processed by the particularprocessing system is significantly reduced.

Yet another problem found in prior art chemical feed systems is theexcessive consumption of chemical fluids. As the chemical fluids aredepleted from the storage tanks and the tanks replaced or refilled, theopportunity for leakage or spillage is greatly increased.

Still another common problem found in most prior art chemical feedsystems is that they are not contained within explosion-proof ventedenclosures. The storage tanks, for example, are frequently left in theopen on the facility floor. This lack of self-containment creates twoother problems. First, a greater amount of facility floor space isdevoted to components of the feed chemical system. Second, the potentialfor explosion or fire is increased. The chemical fluid is flammable andmust be contained in a properly vented explosion-proof enclosure. Whenthe tanks are left in the open, proper precautions to ensure adequateventilation may be overloaded. Also, the storage tanks are not likely tobe contained within an explosion-proof container. Furthermore, theappropriate fire prevention equipment may not be installed proximate tothe storage tanks. These also lead to regulatory violations and fines,as well as increased insurance liability costs.

Accordingly, there is a definite need in the art for a continuous feedchemical system which overcomes the problems of the prior art.

SUMMARY

The present invention comprises a continuous feed, chemical switchingunit for controlling the chemical delivery from two or more chemicalstorage canisters or bottles and which automatically switches over to afull bottle upon detection of an empty bottle. The system furtherincludes a plural container reservoir for containing a predeterminedvolume of a chemical fluid. The reservoir is in fluid communication witha provided processing system. The reservoir is provided with pluralityof level sensors for monitoring the fluid level in the reservoir whereinat least one level sensor is in electronic communication with theprovided processing system whereby if the level sensor is energized thenthe operation of the processing system is halted, and the other levelsensors communicate reservoir level information to a control unit. Aplurality of chemical fluid containers for storing the fluid areprovided wherein the containers are in independent fluid communicationwith the reservoir. Inert-gas actuated isolation valves are provided forisolating the fluid containers from the reservoir. A vacuum source isprovided for drawing a vacuum on the reservoir. The vacuum source iscontrolled via an inert-gas actuated isolation valve for isolation fromthe reservoir. The control unit is responsive to electrical signals fromthe level sensors, an input power signal, and a plurality of usercommands, and is operative to generate signals to actuate the vacuumsource isolation valve and the container isolation valves whereby thecontainer isolation valves are positioned so as to alternate chemicalfluid flow from one container then another. Finally, an explosion-proofenclosure is provided for housing the components of preferred embodimentof the present invention, wherein the enclosure is fitted with anexhaust device to vent explosive gases from the enclosure and is alsoequipped with a fire extinguishing device.

An advantage of the present invention is that it supplies a continuousand non-interrupted flow of chemical feed thereby obviating themisprocessing, excessive consumption and waste, and reduced throughputproblems found in prior art systems. The plurality of chemical fluidcontainers allows at least one full fluid container to always be on"full standby" while the other container is "on-line" supplying theprocessing system. When the "on-line"container is depleted, the controlunit places the "full standby" container to an "on-line" state whileplacing the previously "on-line" container into an "empty standby"state, thereby allowing the empty container to be replenished orreplaced with "full standby" container.

Another advantage of the present invention is that it is interlockedwith the processing system. In the event of a system anomaly, theprocessing system will be shut down and no misprocessing or waste ofchemical fluid will occur.

Yet another advantage of the present invention is that the level sensorsare interlocked with an alarm or another active device that can beremotely or locally situated. If a system anomaly occurs or all thecontainers are depleted, operators of the chemical feed system can bewarned and appropriate action taken. Alternately, the signals from thelevel sensors can be used to actuate an automatic device that canreplenish the chemical fluid or resolve the anomaly.

Still another advantage of the present invention is that it isself-contained. When packaged into an enclosure, the components take upless facility floor space and the fire prevention devices and exhaustsystem can be efficiently installed to service the entire continuousfeed chemical system rather than distributed over a wide spread area.

These and the other advantages of the present invention will no doubtbecome apparent to those skilled in the art after having read thefollowing detailed description of the preferred embodiment illustratedin the several figures of the drawing.

DRAWINGS

FIG. 1 is a block diagram schematically illustrating a typical prior artfeed chemical delivery system.

FIG. 2 is a block diagram schematically depicting a continuous feedchemical delivery system of the present invention.

FIG. 3 is a schematic block diagram illustrating the preferredembodiment of a switching unit (i.e. item 200 of FIG. 2).

FIG. 4 is a block diagram schematically depicting a control PCB (i.e.item 302 of FIG. 3).

FIGS. 5A-5B show a two part circuit diagram illustrating the best modeenablement of the control PCB depicted in FIG. 4.

FIG. 6 is a circuit diagram illustrating the best mode enablement of aremote alarm (i.e., item 213 of FIG. 2).

DETAILED DESCRIPTION OF THE BEST MODE

A continuous feed chemical delivery system 220 is schematically depictedin FIG. 2. The system 220 includes a switching unit 200, containedwithin a cabinet 201, wherein the unit 200 is in fluid communicationwith a typical prior art processing system 104. The pumping system 106delivers a chemical fluid (not shown) from the unit 200 to thephotoresist processing system 104. The pumping system 106 draws thefluid from the unit 200 via a suction pipe 108, and discharges the fluidto the processing system 104 via a discharge pipe 109.

A preferred embodiment of the switching unit 200 is used for servicingand supporting an IC wafer fabrication process. More particularly, theunit 200 is used to store photo-resist material and support aphoto-resist spin-coating processing system that is used for IC waferfabrication. However, it is understood that implementation of the unit200 is not limited to supporting only this particular process and theswitching unit may be used for supporting a variety of other processesincluding but not limited to use in combination with an acid developer,an acid processor, or use in a variety of bulk refill processoperations. Similarly, the switching unit may be used to control thecontinuous feed of a wide variety of fluids or chemicals.

The switching unit 200 is also communicatively coupled with theprocessing system 104 via a process interlock signal line 216. When asystem anomaly occurs such as, for example, where both chemical supplybottles are empty or the system malfunctions, the anomaly condition iscommunicated to the processing system 104 via signal line 216.

The switching unit 200 has several other input and output interfaces.The unit 200 is communicatively coupled with a time set device ("Timer")205, a reset device ("Reset") 207, a power supply device ("PowerSupply") 209, a vacuum source 211, an alarm 213, and a plurality ofinert gas storage containers 215, 217.

The time set device 205 provides a variable time base adjustment toaccommodate a variety of fluid viscosities that are handled by theswitching unit 200. The device 205 is in electronic communication withthe switching unit 200 via a time set signal line 202. The device 205,can be located at an either a local or a remote site with respect to theswitching unit 200. In the preferred embodiment illustrated in FIG. 2,the time set device 205 is located at a site remote to the switchingunit 200.

After an alarm condition has been investigated and corrected, the resetdevice 207 is used to clear an alarm condition and reset the electroniccomponents of unit 200. The device 207 is in electronic communicationwith the switching unit 200 via a reset signal line 204. The resetdevice 207 can be located at a either a local or a remote site (asillustrated in FIG. 2) with respect to the switching unit 200. However,in the preferred embodiment illustrated in FIG. 2, the reset device 207is located at a site remote to the switching unit 200.

Another input device is a power supply device 209 which is in electroniccommunication with the switching unit 200 via a power supply signal line206. The power supply device 209 provides 12 volt DC power for aswitching unit controller (described in detail below with reference toFIG. 3).

An output device is an alarm 213 which is in electronic communicationwith the switching unit 200 via an alarm signal line 208. The alarm 213provides an audible or visual alarm when a system anomaly condition hasoccurred or the switching unit 200 requires servicing. The alarm device213 can be located at a either a local or a remote site (as illustratedin FIG. 2) with respect to the switching unit 200. In the preferredembodiment illustrated in FIG. 2, the alarm device 213 is located at asite remote from the switching unit 200.

An external vacuum source 211 is communicatively coupled to theswitching unit 200 via a vacuum output pipe 210. The vacuum source drawsa vacuum on some chemical fluid containing components included withinthe switching unit 200.

The switching unit 200 is also communicatively coupled to a plurality ofinert gas storage containers 215 and 217. As is shown in the drawings, apreferred inert gas is nitrogen (N₂). Each storage container providesinert gas to the switching unit 200 and is in independent fluidcommunication with the unit 200. Thus, container 215 is in fluidcommunication with the switching unit 200 via a bottle #2 inert gassupply pipe 212; container 217 is in fluid communication with theswitching unit 200 via a bottle #1 inert gas supply pipe 214. It shouldbe noted that although only two inert gas storage containers have beenshown in FIG. 2, any number of storage containers could have beenillustrated with only minor modification to the present embodiment.

Finally, the switching unit cabinet 201 is communicatively coupled withan exhaust fan 221, via a cabinet exhaust pipe 203. The exhaust fan 221vents the switching unit cabinet 201 exhausting flammable gases from thecabinet 201 thereby preventing explosions and fires.

The switching unit 200 is schematically depicted in FIG. 3. It iscontained within the cabinet 201, and includes the following components:a printed circuit board 300 containing control logic (hereinafter"control PCB 300"), a reservoir 310, a first fluid chemical bottle 332(Bottle 1), a second fluid chemical bottle 340 (Bottle 2), and aplurality of valves. While only two chemical fluid bottles, orcontainers, have been illustrated in the preferred embodiment, it willbe appreciated by those skilled in the art that any greater number offluid bottles may be installed into the switching unit as desiredwithout sacrificing its operational capability or efficiency. Alsoprovided to the cabinet is a fire extinguisher device designatedgenerally as 302. The self-contained fire extinguishing device 302operates in the known way and is preferably activated at a preselectedthreshold temperature.

The reservoir 310 contains a quantity of chemical fluid 102 and is influid communication with the process system 104 (FIG. 1), with thecontainers 332 and 340, and with the vacuum source 211 (FIG. 2). Thepumping system 106 draws fluid 102, via pipeline 108, from the reservoirand discharges fluid 102, via pipeline 109, to the process system 104.The vacuum source 211 draws a vacuum on the reservoir 310 via the vacuumoutlet pipe 210, a vacuum source pipe 327 and 328. The vacuum source 211can be isolated from the reservoir 310, by either a vacuum source manualisolation valve 326 or a vacuum source isolation valve 323. Thereservoir 310 is also in fluid communication with bottle #1, item 332,via a chemical fluid pipe 331 and 336. In addition, the reservoir 310 isin fluid communication with bottle #2, item 340, via a chemical fluidpipe 343 and 344. Thus, when the reservoir 310 is under a vacuum, thefluid 102 stored in bottle 332 (or 340) flows to the reservoir via pipes336 and 331 (or 343 and 344), unless a bottle #1 isolation valve 333 (orbottle # 2 isolation valve 341) is closed.

The bottle #1 isolation valve 333 is a gas actuated solenoid valve andincludes a bottle #1 isolation solenoid 334 and an actuation rod 335.Similarly, the bottle 2 isolation valve 341 includes a bottle #2isolation solenoid 342 and an actuation rod 345. The solenoid 334 is influid communication with the inert gas storage container 217 via aninert gas supply pipe 358 and the bottle 1 inert gas supply pipe 214.The solenoid 334 is isolated from the container 217 by an inert gasisolation valve 355. In similar fashion, the solenoid 342 is in fluidcommunication with the inert gas storage container 215 (FIG. 2), via aninert gas supply pipe 352 and the container 2 inert gas supply pipe 212.The solenoid 342 is isolated from the container 215 by an inert gasisolation valve 351.

Included within the reservoir 310 is a magnetically activatedHall-effect sensor float array consisting of three sensors, fordetermining the level of chemical fluid 102 in the reservoir 310. Anempty-level (or process interlock) sensor 316 is installed at the lowestin the reservoir 310, and is in electronic communication with theprocessing system 104 via the signal line 216. A fill-level sensor 314is situated at an intermediate or center level and is in electroniccommunication with the control PCB 300, via a fill-level sensor signalline 318. A full-level sensor 312 is mounted at the highest level of allthree sensors, and is in electronic communication with the control PCB300, via a full-level sensor signal line 320.

The preferred sensor array is made from stainless steel and constitutesthe only metal component in the chemical flow path excluding theselected pump 106. The valves, tubings and fittings used throughout thechemical pathway are preferably composed of Delrin™ or Teflon™ plasticso that contamination or chemical incompatibility problems are avoided.

The control PCB 300, in a manner to be described below, switches thechemical fluid bottle (either 332 or 340) that is used to supply thefluid 102 to the reservoir 310 and ultimately to the processing system104. By switching bottles 332 or 340 in a timely manner, the processingsystem 104 is supplied with a continuous or uninterrupted supply offluid 102, thereby eliminating the problems found in prior art feedchemical systems.

The control PCB 300 is in electronic communication with the full-levelsensor 312, via the signal line 320, and the fill-level sensor 314, viathe signal line 318. The PCB 300 is also in electronic communicationwith the time set device 205 (via signal line 202), the reset device 207(via the signal line 204), the power supply device 209 (via signal line206), and the alarm 213 (via signal line 208). In addition, the PCB 300is in electronic communication with a vacuum source isolation solenoid324, via a vacuum source isolation solenoid signal line 322. Thesolenoid 324 is mechanically connected to the isolation valve 323, viaan actuation rod 325. Also, the PCB 300 is in electronic communicationwith a inert gas isolation solenoid 350, via a bottle 2 gas isolationsolenoid signal line 348, and with a inert gas isolation solenoid 356,via a bottle 1 gas isolation solenoid signal line 354. The solenoid 350is mechanically connected to the isolation valve 351, via an actuationrod 349; while the solenoid 356 is mechanically connected to theisolation valve 355, via an actuation rod 357.

Finally, the PCB 300 is in electronic communication with an operatordisplay panel 360. The panel 360 receives input signals to illuminate aplurality of light emitting diodes (LED's) via a bottle #1 LED signalline 362, a bottle #2 LED signal line 364, a remote alarm LED signalline 368, and a vacuum source isolation solenoid LED signal line 366.

The control PCB 300 of FIG. 3 is depicted in a block diagram in FIG. 4.As shown, the control PCB 300 includes in operative interconnection abottle active selector logic generally indicated at 400, a bottle #1empty indicator 416, a bottle #2 empty indicator 418, an alarm control420, a reservoir fill control 422, a float latch 432, a reset control434, a fill trigger disable timer 436, a fill trigger 430, a fillduration timer 428, a fill duration indicator 426, and a bottle switchlatch 424. The bottle active selector logic 400 is shown to furtherinclude in operative interconnection NAND gate 402, NAND gate 404, abottle select latch 406, an inverter 408, an inverter 410, a bottle 1gas isolation solenoid driver 412, and a bottle 2 gas isolation solenoiddriver 414. The outputs of the control PCB 300 are as shown to the righthand side of FIG. 4, not shown, however, are the connections to thepower supply and ground.

NAND gate 402 is in electronic communication with the inverter 408, thetimer 436, the bottle switch latch 424, the bottle select latch 406, thealarm control 420 and the alarm 213 as shown. The gate 402 is responsiveto signal input received from the inverter 408 via a bottle #1 activesignal line 450, the timer 436 via a bottle switching inhibit signalline 483, the latch 424 via a full bottle switch inhibit signal line466. The gate 402 generates an output to the latch 406 via a bottle #1select signal line 454, to the control 420 via the alarm signal line208, to the alarm 213 via the alarm signal line 208.

In similar fashion, as shown, the NAND gate 404 is in electroniccommunication with the latch 424, the timer 436, the inverter 410, andthe latch 406. The NAND gate 404 is responsive to inputs from the latch424 via signal line 466, the timer 436 via the signal line 483, theinverter 410 via a bottle #2 active signal line 452, and operative togenerate an output to the latch 406 via a bottle 2 select signal line456.

The bottle select latch 406 is communicatively coupled to the gates 402,404, and the inverters 408, 410. Latch 406 receives inputs from the gate402, via the signal line 454, and from the gate 404, via the signal line456. The latch 406 is operative to generate an output to the inverter408, via a bottle #1 select signal line 458, and to the inverter 410,via a bottle #2 select signal line 460.

The inverter 408 is communicatively coupled to the bottle select latch406, the solenoid driver 412, and the gate 402. The inverter 408receives input from the latch 406, via the signal line 458, andgenerates output to the driver 412 and the gate 402, via the signal line450.

In similar fashion, the inverter 410 is shown electronically coupled tothe latch 406, the driver 414, and the gate 404. The inverter 410receives input from the latch 406, via the signal line 460, andgenerates an output to the gate 404 and the driver 414, via the signalline 452.

The driver 412 is electronically coupled to the inverter 408, theindicator 416, the inert gas isolation solenoid 356, and a bottle #1 LED(not shown) mounted on the panel 360. The driver 412 responds to inputfrom the inverter 408, via the signal line 450, and generates an outputto the solenoid 356 and the indicator 416, via the signal line 354, andalso an output to the bottle #1 LED, via the signal line 362.

The driver 414 is communicatively coupled to the inverter 410, the inertgas isolation solenoid 350, and a bottle #2 LED (not shown) mounted onthe operator panel 360. The driver 414 receives input from the inverter410 via the signal line 452. The driver 414 outputs signals to thebottle #2 LED via the signal line 364, and to the solenoid valve 350 andthe indicator 418, via the signal line 348.

The bottle switch latch 424 is communicatively coupled to the reservoirfill control 422, and the gates, 402, 404. The latch 424 receives inputfrom the fill control 422 via a bottle switch signal line 464, andgenerates an output to the gates 402, 404 via a full bottle switchinhibit signal line 466.

The fill control 422 is communicatively coupled to the latch 424, thefill duration timer 428, the float latch 432, the vacuum sourceisolation solenoid 324, and a fill LED (not shown) mounted on the panel360. The fill control 422 responds to input from the latch 432, via afill reset signal line 470, and from the timer 428 via a fill durationsignal line 472. The fill control 422 is operative to generate a signalto the latch 424 via the signal line 464, to the isolation solenoid 324via the signal line 322, and to the fill LED via the signal line 366.

The alarm control 420 is communicatively coupled to the gate 402, theindicators 416 and 418, the reset device 207, a remote alarm LED (notshown) mounted on the panel 360. The alarm control 420 receives inputfrom the gate 402 via the signal line 208, and from the reset device 207via the reset signal line 204; the control 420 generates an Output tothe indicators 416 and 418 via a bottle empty indicator driver signalline 462, and to the remote alarm LED via the signal line 368.

The float latch 432 is electronically coupled to the fill control 422,the reset control 434, the full level sensor 312, and the fill levelsensor 314. The latch 432 receives input from the sensor 312 via thesignal line 320, and from the sensor 314 via the signal line 318. Thelatch 432 generates an output to the fill control 422 and the resetcontrol 434 via a fill reset signal line 470.

The reset control 434 is electronically coupled to the fill durationtimer 428, the fill trigger 430, and the float latch 432. The control434 receives input from the latch 432 via the signal line 470, and fromthe fill trigger 430 via a restart signal line 478. The reset control434 generates an output to the timer 428 via a restart signal line 476.

The fill duration timer 428 is communicatively coupled to the fillduration indicator 426, the fill control 422, the reset control 434, thetime set device 205, and the fill trigger disable timer 436. The timer428 receives input from the reset control 434 via the signal line 476,and from the device 205 via the signal line 202. The timer 428 generatesan output to both the fill control 422 and the indicator 426, via thesignal line 472, and to the disable timer 436 via a fill durationexceeded trigger signal line 474.

The disable timer 436 is electronically coupled to the fill trigger 430,and the fill duration timer 428. The disable timer 436 receives inputfrom the timer 428 via the signal line 474. Timer 436 generates anoutput to the trigger 430 via a time output signal line 480.

Fill trigger 430 is communicatively coupled to the disable timer 436,the reset control 434, the gate 402. The trigger 430 receives input fromthe gate 402 via the signal line 483, and from the disable timer 436 viathe signal line 480. The trigger 430 generates an output to the resetcontrol 434 via the restart signal line 478.

FIGS. 5A-5B illustrate a circuit diagram depicting the best modeenablement of the control PCB 300 of FIG. 4. It should be noted thatindividual devices have been collected into the functional groupingsidentified in FIG. 4. Thus, the circuit diagram illustrated in FIGS.5A-5B includes the following functional groups: The timer 436, the resetcontrol 434, the fill trigger 430, the fill duration timer 428, the fillduration indicator 426, the float latch 432, the reservoir fill control422, the latch 424, the alarm control 420, the NAND gate 402, the NANDgate 404, the latch 406, the inverter 408, the inverter 410, the driver412, the driver 414, the bottle 1 empty indicator 416, and the bottle #2empty indicator 418.

The timer 436 includes a timer device U2 with the signal line 474 as aninput and the signal line 480 as an output.

The reset control 434 includes an inverter U5C and a two-input NOR gateU6B. The inputs to the control 434 include the signal line 470 and thesignal line 478; the output from control 434 is the signal line 476.

The trigger 430 includes a timer device U3 and has as input the signalline 480 and as output the signal line 478.

The timer 428 includes a timer device U1 and has as inputs a signal line202, and a signal line 476; the signal line 474 is output from the timerU1.

The fill duration indicator 426 includes a light emitting dial (LED)device D1 and has an input signal line 472.

The fill control 422 includes an inverter device U5A, an inverter deviceU5B, a two-input NOR gate device U6A, a three-input NAND gate deviceU9C, a transistor device Q2, and a LED device D4. The fill control 422has two inputs. The signal line 472, and the signal line 470; thecontrol 422 has four outputs, a signal line 464A, a signal line 464B,the signal line 322, and the signal line 366.

The latch 424 includes a two-input NAND gate device U4C, and a two-inputNAND gate device U4B. The input to the latch 424 are the signal lines464A and 464B; the output from the latch 424 is the signal line 466.

The alarm control 420 includes a two-input NAND gate device U8A, atwo-input NAND gate device U8B, a two-input NAND gate device U8C, atransistor device Q1, and a LED device D5. The alarm control has twoinputs, the signal line 204 and the signal line 208; the control 420 hasone output, the signal line 368.

The NAND gate 402 is a three-input NAND gate device U9B. The inputsignal lines include the signal line 450, the signal line 483, and thesignal line 466. The output line is the signal line 454.

Similarly, the NAND gate 404 is a three-input NAND gate device U9A. Theinput signal lines include the signal line 452, the signal line 466, andthe signal line 483. The output from the gate 404 is the signal line456.

The latch 406 includes a two-input NAND gate device U7C, and a two-inputNAND gate device U7B. The latch 406 has as input the signal line 454,and the signal line 456; the outputs are the signal line 458, and thesignal line 460.

The inverter 408 is a two-input NAND gate device U7A and has as inputthe signal line 458, and as output the signal line 450. The inverter 410is a two-input NAND gate device U7B. The inverter 410 has as input thesignal line 460, and as output the signal line 452.

The driver 412 includes a transistor device Q3, and a LED D3. The inputsto the driver 412 is the signal line 450; the output from the driver 412are the signal line 354, and the signal line 362. The driver 414includes a transistor device Q4, and a LED D2. The signal line 452 isinput to the driver 414; the signal lines 348 and 364 are outputs fromthe driver 414.

The indicator 416 includes a two-input NOR gate device U6E, an inverterU5E, and a LED D5. The indicator 418 includes a two-input NOR gatedevice U6E, an inverter device U5E, and a LED D5. There are two-inputsto the indicator 418, the signal line 348, and the signal line 462. Theindicator 416 receives two-inputs, the signal line 354, and the signalline 462.

FIG. 6 illustrates a circuit diagram of alarm 213, wherein the alarm 213is communicatively coupled to the gate 402 via a connector 7. The alarm213 includes in electrically operative combination an opto-isolator610A, a reset switch 622, and alarm latch 627, an inverter 630, aspeaker control 636, and a speaker 634. The opto-isolator 610A serves toisolate the alarm control 420, the NAND gate 402, and the latch 406 fromthe speaker 634 and the speaker control 636. It should be noted that asmany as twelve opto-isolators may be utilized although only six havebeen shown in FIG. 6. The opto-isolator is communicatively coupled viaan alarm signal line 608A to the connector 7. The opto-isolator 610A isalso communicatively coupled, via a latch set signal line 614 to thealarm latch 627. The alarm latch 627 includes a two input NAND gatedevice U1A, and a two input NAND gate device U1B. Device U1A iscommunicatively coupled to a power source 621 via the signal line 614;while device U1B is coupled to the power source 621 and the reset switch622 via a latch reset signal line 620. The latch 627 is coupled to theinverter 630 via a latch output signal line 628. The inverter iscommunicatively coupled to the speaker control 636 via an inverteroutput signal line 632. A speaker source is communicatively coupled tothe power source 621 via a speaker power signal line 633.

In operation (referring to FIGS. 5A and 5B), the switching sequence(i.e.. switching from an empty bottle of chemical to a full bottle)begins with the NAND gates 402 and 404. The three inputs to the twogates are:

1) The input from bottle one or bottle two active (via signal lines 450or 452) wherein an "active" signal input is equal to a high;

2) The input from fill trigger disable timer 436 (via signal line 483).Fill trigger disable timer 436 is approximately 2 seconds in durationand prevents the immediate bottle switch at the expiration of time 428.Input from fill trigger disable timer 436 is low while timing.

3) This input is from the latch 424 to prevent a bottle change when thereservoir is full.

These three inputs control the bottle switching and it takes all threeinputs in an active state (i.e., high) to cause the output to go low,which is required to make the bottle switch occur. This will happen ononly one of the two NAND gates 402, 404 at a time.

The outputs of NAND gates 402, 404 (i.e., signal lines 454, 456respectively) are the inputs to the bottle select latch 406 which allowsonly one bottle to be active at any given time.

The selected inverter for the active bottle (that is, either inverter408 or inverter 410) inverts the output signals of the bottle selectlatch 406 thereby setting the correct base drive voltage polarity forthe selected solenoid driver transistor (i.e.. Q4 or Q3 shown on FIG.5A).

The selected solenoid driver 414 (or 412 energizes solenoids 350 (or356) and permits inert gas, stored in container 215 (or 217) to passthrough supply pipe 212, 352 (or 214 and 358) thereby actuating thebottle 2 isolation solenoid 342 (or the bottle 1 isolation solenoid334). This actuation of the solenoid 342 (or 334) opens the isolationvalve 341 (or 333) thereby allowing chemical fluid contained in bottle#2, 340 (or bottle #1, 332) to pass into the reservoir 310 andultimately to the processing system 104.

The reservoir fill control 422 is activated when the fill-level sensor314 indicates that the fluid 102 has been depleted and the reservoir 310needs to be filled. The float latch 432 is set by the fill-level sensor314 and remains latched until reset by the full-level sensor 312. Whenreset by full-level sensor 312, the float latch 432 supplies a triggersignal, via signal lines 470 and via reset control 434 and signal line476, to start fill duration timer 428.

Fill duration timer 428 times the duration of the filling of thereservoir. In the present example, the reservoir 310 must be filledwithin approximately seven minutes. If the full-level sensor 320 isactivated prior to the expiration of the seven-minute timer, then thefill duration timer 428 is locked out by a low signal from the floatlatch 432 and a bottle switch would not occur. If the seven-minute timeduration of fill duration timer 428 does expire, a trigger from timer428 via signal line 474 would start the fill trigger disable timer 436.After a two-second period of time, fill trigger disable timer 436 stopsand fill trigger 430 starts. The duration of fill trigger 430 isapproximately 0.7 seconds and is used as a switch-over trigger for thebottle switching (i.e.. as an input to the gates 402 and 404) and therestart trigger for fill duration timer 428 (via reset control 434). Ifthe full-level sensor 312 is not set during the time period for fillduration timer 428, it is assumed that the active bottle is empty andthe standby bottle becomes the active bottle.

The latch 424 is for enabling or disabling a bottle switch. The latch424 will not allow any signal from the full-level sensor 312 andfill-level 314 after the initial activation. This eliminates randomswitching.

The alarm circuitry is incorporated to provide indications of a bottleswitch so that empty bottles can be changed in a timely fashion. Thealarm control 420 only drives the LED's mounted on the panel 360 andshould not be confused with the remote alarm circuit (illustrated inFIG. 6) which provides an alarm preferably audible at a remote location.The LED's on panel 360 provide an indication of the switcher status.When a bottle switch occurs, the alarm LED bottle is illuminated; theLED for bottle 1 or 2, depending on which bottle is considered empty, isalso illuminated. This alarm condition can only be reset from the resetdevice 207 (FIG. 3) mounted on the panel 360. The remote alarm 213 (FIG.3) is also reset by the device 207. In an effort to minimize errors thealarm must be addressed at the resist switching unit so that the emptybottle is replaced before the alarm is reset.

In normal operation there is no alarm condition. The state of the alarmsignal line 208 is normally high or in the "1" state. Consequently, thestate of the signal lines 608A, 612A, 614, 615, and 620 are all in thehigh or "1" state. Under alarm conditions, the state of the signal line208 changes to a low or "0" state. Thus, the state of the signal lines608A, 612A, and 614, all move to a correspondingly low or "0" state. Thestate of the signal line 615 goes to a low state causing the state tochange in the signal line 628 to a low or "0" state. The state of thesignal line 632 is correspondingly changed to a high or "1" statethereby causing the speaker control 636 to pass power via the signalline 633 to the speaker 634 thereby causing an audible alarm sound. Toreset or silence the audible alarm, the reset switch 622 is closed. Inthe closed position, power passes through the switch 622 to groundthereby causing the state of the signal line 620 to go from a previouslyhigh state to a low state. This state change on the reset signal line620 causes the state of the signal line 628 to change from a low to ahigh state. This causes the state of the inverter output signal line 632to go to a low state thereby causing the speaker control 634 to isolatepower from the speaker 634 thereby silencing the audible alarm.

Although a preferred embodiment of the present invention has beendisclosed above, it will be appreciated that numerous alterations andmodifications thereof will be apparent to those skilled in the art afterhaving read the above disclosures. It is therefore intended that thefollowing claims be interpreted as covering all such alterations andmodifications as fall within the true spirit and scope of the invention.

What is claimed is:
 1. A continuous feed, chemical system for supplyingan uninterrupted flow of chemical fluid to a process tool comprising inoperative combination:a) a plurality of removable bottles, eachcontaining a quantity of chemical fluid and having a fluid outlet line,said plurality of bottles including a first chemical fluid bottle and asecond, alternate standby chemical fluid bottle; b) a reservoir disposeddownstream of said plurality of chemical fluid bottles for holding apredetermined amount of chemical fluid, said reservoir having an airoutlet port, a fluid outlet port and a plurality of fluid inlet ports,each of said fluid inlet ports are communicatively coupled withrespective ones of said chemical fluid bottle fluid outlet lines; c)conduit means for communicatively coupling said fluid outlet port ofsaid reservoir to a chemical fluid receiving port of said process tool;d) pump means disposed along said conduit means for transferringchemical fluid from said reservoir to said process tool via said conduitmeans; e) vacuum means connected to said air outlet port of saidreservoir and operative to generate a negative pressure within saidreservoir sufficient to draw chemical fluid from an active chemicalfluid bottle; f) a plurality of bottle selector valve means each ofwhich are associated with individual ones of said chemical fluid bottlefluid outlet lines, each of said valve means having two operationalmodes including i) a first active mode for permitting fluid flow from anassociated chemical fluid supply bottle to said reservoir, and ii) asecond nonactive mode for preventing fluid flow from an associatedchemical fluid supply bottle to said reservoir; g) sensor means formonitoring the fluid level within said reservoir, said sensor meanscomprises a float level sensor array including a first full-levelsensor, a second fill-level sensor and a third empty-level sensor,wherein: i) activation of said full-level sensor disables said vacuummeans; ii) activation of said fill-level sensor re-enables said vacuummeans and signals an alarm condition to a control means to selectivelyoperate said valve means for bottle switching operation from said firstbottle to said second standby alternate bottle; iii) activation of saidempty-level sensor disables all of said bottle selector valve means andsaid vacuum means, and provides an interlock signal to said process toolto stop continued processing; and h) an electronic control meanscommunicatively coupled with each of said valve means and said sensormeans for selectively enabling the mode operation of each of said valvemeans to switch the status of a bottle from which chemical fluid isactively being withdrawn to a nonactive status and the standby status ofa full alternate bottle to active withdrawal of chemical fluid therefromin response to signal information received from said sensor means.
 2. Acontinuous feed, chemical system as in claim 1 which includes:a) a timeset device for providing a variable time base adjustment for the bottleswitching operation of said electronic control means to accommodate avariety of fluid viscosities; b) an alarm responsive to said alarmcondition for signaling to an operator that a current fluid sourcebottle is empty and needs replacement; and c) a reset device forproviding a clear alarm signal to said control means which thengenerates a reset restart signal to indicate that said current fluidsource bottle has been replaced by a full bottle.
 3. A continuous feed,chemical system as in claim 2 wherein said control means includes:a) afloat latch responsive to signals received from said full-level andfill-level sensors and operative to generate a fill reset signal; b)reset control logic responsive to said fill reset signal and operativeto generate a reset signal; c) a fill duration timer responsive to saidtime set device and said reset signal and operative to generate a fillduration signal, a switching inhibit signal, and a reset restart signal;d) reservoir fill control logic responsive to said fill reset signal andsaid fill duration signal and operative to generate a bottle switchsignal and a reservoir fill signal; e) a switch latch responsive to saidbottle switch signal and operative to generate a bottle switch inhibitsignal; f) a switcher responsive to said bottle switch signal and saidbottle switch inhibit signal and operative to generate a first bottleswitch signal, a second bottle switch signal, and a bottle empty alarmsignal; and g) alarm control logic for monitoring said alarm conditionand responsive to said bottle empty alarm signal and operative togenerate an alarm signal.
 4. A continuous feed, chemical system as inclaim 3 wherein said switching unit is enclosed within a sealable,explosion-proof cabinet and wherein said cabinet includes:a) means forextinguishing flames generated by combustion of said chemical fluid; andb) means for exhausting combustible gases generated by said chemicalfluid to an outside exhaust plenum.
 5. A continuous feed, chemicalsystem as in claim 4 which includes a panel display means mounted to anoutside surface of said cabinet for display of alarm and other systeminformation.
 6. A continuous feed, chemical system as in claim 1 whereineach of said bottle selector valve means include an inert gas activatedsolenoid valve.